Plastic Injection Double-Face Flat-Top Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Plastic Injection Double-Face Flat-Top Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Product Positioning
Motek introduces dedicated injection molds for double-face flat-top plastic pallets. Double-face flat-top pallets feature flat decks on both upper and lower surfaces, allowing dual-side use. Combined with four-way forklift entry openings, they offer stacking stability and space utilization efficiency—widely used in food, pharmaceutical, cold-chain, and automated warehousing applications. Compared with single-face or grid double-face pallet molds, the core challenges of double-face flat-top pallet molds lie in synchronous flatness control of both faces, alignment precision of upper and lower cavities, and coordinated timing of forklift opening core-pulling and ejection. Motek configures dedicated solutions around double-face cavity layout, balanced hot runner filling, and composite demolding systems, helping customers achieve stable mass production of double-face flat-top pallets.
Core Specifications
| Item | Specification |
|---|---|
| Applicable Plastics | HDPE / PP (high-rigidity, low-temperature resistant grades) |
| Mold Material | P20 / 718H / 2738 (cavity and core), key load-bearing areas HRC 32–36 |
| Number of Cavities | 1×1 (single cavity for large pallets) |
| Mold Life | 500,000–1,000,000 shots |
| Cycle Time | Depending on pallet size and cooling design; industry reference for double-face pallets can reach the 69-second range |
| Injection Machine | 1000T–3000T (depending on pallet size) |
| Runner System | Hot runner (multi-point gates, balanced filling of double-face flat areas) |
| Ejection Method | Ejector pins/plates with hydraulic drive, dual-face demolding timing linkage |
Product Features
Synchronous Forming and Alignment Precision Control for Double-Face Flat Surfaces.
Double-face flat-top pallets require flat surfaces on both upper and lower faces, and the mold must ensure precise alignment of upper and lower cavities—otherwise misalignment or uneven thickness will occur on both faces. Motek adopts high-precision guide pin and guide bushing fit (fit clearance H7/g6), ensuring accurate upper-lower cavity alignment during mold closing and protecting cavity edges from damage. For double-face full-grid or flat structures, cavity and core insert interchangeability tolerance is controlled within ±0.01 mm for rapid repair and replacement.
Coordinated Timing of Forklift Opening Core-Pulling and Demolding.
The four-way forklift entry openings of double-face pallets must be formed between upper and lower molds, and the core-pulling mechanism design directly affects demolding smoothness and product strength. In mature industry solutions, a long-short core-pulling piece staggered butt-joint demolding mechanism is adopted: long and short core-pulling pieces are arranged in 90° annular arrays, staggered and butt-jointed, forming a fully closed #-shaped configuration—eliminating the need for interlocking inserts while ensuring easy demolding and good pallet product strength. Motek configures core-pulling piece quantity and action timing according to the pallet's fork opening distribution, ensuring complete forming of all-direction fork openings with no scratching during demolding.
Warpage Control for Double-Face Flatness.
Both faces of double-face flat-top pallets must remain flat; uneven cooling or shrinkage differences can easily cause one face to bulge and the other to concave. Motek evaluates shrinkage distribution across both faces through mold flow analysis, applying reverse deformation compensation design to the cavity, ensuring finished pallet flatness is controlled within ±2 mm/m. The cooling system uses zoned water circuits covering upper and lower panel areas and intermediate support structures separately, equalizing cooling rates between thick-wall and thin-wall areas. Cooling water circuits must pass 1.2 MPa pressure testing for 30 minutes without leakage.
Balanced Filling with Hot Runner System.
Double-face flat-top pallets have long melt flow paths and large coverage areas, making it difficult for single-point gates to ensure simultaneous uniform filling of both faces. Motek adopts a multi-point hot runner system, configuring gate quantity according to pallet size (large double-face pallets can have up to 25 feed points), ensuring balanced melt flow paths to all areas and preventing localized strength reduction or warpage caused by uneven filling. Industry experience shows that three-layer manifold hot runner systems can further optimize melt flow path balance.
Hardness and Wear Treatment for Load-Bearing Areas.
Key load-bearing areas of double-face flat-top pallets (around forklift openings, support leg connections) require sufficient hardness and wear resistance. Motek applies nitriding treatment to key cavity areas, with nitrided layer depth of 0.2–0.3 mm and surface hardness HRC 32–36, ensuring dimensional stability beyond 800,000 shots. For high-volume requirements, 718H or 1.2344ESR can be selected for cavity and core to further enhance wear life.
Full-Dimension CMM Inspection and Quality Control.
After mold processing is completed, Motek provides full-dimension CMM inspection reports, focusing on fork slot spacing (tolerance ±1 mm) and diagonal flatness (≤1.5 mm). Load testing and flatness verification are conducted simultaneously during trial molding, ensuring samples meet dynamic/static/rack load requirements before delivery.
Mold Outer Dimensions Reference
The following table lists double-face pallet mold dimension data available from search materials for reference. Actual mold dimensions vary depending on product specifications, cavity count, and cooling system design. Motek provides customized solutions based on customer pallet 3D drawings and injection machine specifications.
| Product Specification / Notes | Mold Outer Dimensions (mm) | Applicable Injection Machine | Source Type |
|---|---|---|---|
| Double-face pallet (1300×1100×152.5mm) | 2130×1660×1135 | 1000T–3000T | Mold maker |
| Large double-face full-grid pallet (1100×1100×150mm) | Total mold weight approx. 19 tons | Large-tonnage injection machine | Industry achievement |
Applications
Motek plastic injection double-face flat-top pallet molds are suitable for:
- Double-face flat-top pallets for food/pharmaceutical/cold-chain industries
- Double-face pallets for automated storage and retrieval systems (AS/RS)
- Double-face flat-top plastic pallets for export transport
- Standard four-way entry double-face pallets (1200×1000mm, 1100×1100mm, etc.)
- Dual-side use stacking/racking pallets
Service Process
After the customer provides 3D product drawings, load requirements (dynamic/static/rack load), and target output, Motek completes mold flow analysis (including double-face filling balance evaluation, warpage compensation, and core-pulling plans) and mold structure confirmation; cavity steel and hot runner systems are procured according to agreed specifications; progress and key milestones are regularly reported during processing. During trial molding, emphasis is placed on verifying double-face flatness, forklift opening dimensional accuracy, core-pulling demolding smoothness, and load-bearing performance, with samples and CMM inspection reports provided. Before shipment, molds undergo anti-rust treatment and action testing, with water circuit diagrams, hot runner wiring diagrams, consumable parts lists, and maintenance instructions provided. Technical support is available during the warranty period, with lifetime maintenance consultation.
Motek — From double-face flat-top pallets to grid Chuan-character pallets, providing reliable mold solutions for injection molding of logistics and warehousing plastic pallets.
